Robot End Effector for Precise Light Bar Backplane Assembly
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Solution Overview
Problem
The existing labor-based methods for assembling LED light bars in LCD televisions are inefficient and labor-intensive, leading to reduced accuracy and increased operator fatigue due to the large size of the products, which exceeds the maximum operation range of an operator's arm.
Innovation Solution
A light bar assembling device featuring a robot assembling mechanism with a mechanical arm and an end effector equipped with suction cups and positioning pins, which adjusts and accurately assembles light bars onto a backplane, improving efficiency and accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If labor-based methods are used for assembling light bars, then flexibility and adaptability are maintained, but productivity is low and manufacturing precision is reduced
Solution Approach 1:
The patent replaces manual labor-based assembly with an automated robot picking and placing mechanism. The robot system uses suction cups for gripping light bars and positioning pins for precise placement, eliminating manual operation while maintaining high positioning accuracy through automated control systems.
Solution Approach 2:
The adjusting platform automatically adjusts the position of light bars to match the robot's picking position, and the robot automatically positions and places light bars onto the backplane. This self-adjusting and self-positioning capability enables high-speed automated assembly without sacrificing precision.
2Area of stationary object
If the size of television is enlarged, then product functionality is enhanced, but device complexity increases and operator operation becomes difficult
Solution Approach 1:
The patent replaces manual assembly operations with an automated robot system that can reach and assemble light bars on large backplanes. The robot's extended arm and automated positioning capabilities allow it to access areas that would be difficult or impossible for human operators to reach efficiently.
Solution Approach 2:
The patent introduces automated vertical and horizontal movement dimensions through the robot system and adjusting platform, enabling assembly operations on large backplanes without requiring operators to physically access all areas. The system moves components and tools through multiple spatial dimensions to accomplish assembly tasks.
3Quantity of substance
If the number of light bars is increased, then luminous effect is improved, but assembly time increases and productivity decreases
Solution Approach 1:
The patent implements continuous automated assembly operations where the robot picks and places light bars in a continuous sequence without interruption. The adjusting platform continuously adjusts light bar positions, and the robot continuously performs picking and placing actions, eliminating idle time between operations and maintaining constant productive action throughout the assembly process.
Solution Approach 2:
The adjusting platform performs preliminary position adjustment of light bars before the robot picks them up, ensuring that each light bar is pre-positioned for optimal picking. This preliminary preparation eliminates positioning delays during the actual assembly operation, allowing the robot to work continuously at full speed.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The device enhances the efficiency and accuracy of light bar assembly by enabling precise positioning and stable pickup of light bars, reducing operator fatigue and improving the overall assembly process.
Implementation Method 1
each first pick-and-place mechanism includes at least two first suction cup groups, each of which includes at least one first suction cup
Implementation Method 2
at least one first positioning mechanism arranged on the first frame and configured to be insertedly mated with a positioning hole in the light bar
Data Source
AI summary
An end effector and a light bar assembling device having the end effector are provided. The light bar assembling device is configured to assemble a light bar with a backplane, and includes: an adjusting platform configured to carry the light bar to be assembled and adjust a position of the light bar to be assembled on the adjusting platform; and a robot assembling mechanism configured to obtain a light bar after being adjusted in position from the adjusting platform, and assemble the light bar with the backplane, wherein the robot assembling mechanism includes a mechanical arm and an end effector at a free end of the mechanical arm, and the end effector includes: a first connecting seat, a first frame, a first pick-and-place mechanism including at least two first suction cup groups, and a first positioning mechanism including at least two first positioning pins.